An article for use with an apparatus for heating an aerosol generating agent

ABSTRACT

An article for use with an apparatus for heating aerosol generating agent to volatilize at least one component of the aerosol generating agent, the article including a support layer having a first surface, wherein at least a portion of the first surface is rough and an aerosol generating agent on the portion of the first surface that is rough.

PRIORITY CLAIM

The present application is a Divisional Application of U.S. ApplicationNo. 16/492,652, filed Sep. 10, 2019, which is a National Phase entry ofPCT Application No. PCT/EP2018/058195, filed Mar. 29, 2018, which claimspriority from GB Patent Application No. 1705152.5, filed Mar. 30, 2017,which are all hereby fully incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to an article for use with an apparatusfor heating aerosol generating agent.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobaccoduring use to create tobacco smoke. Attempts have been made to providealternatives to these smoking articles by creating products that releasecompounds without actually combusting and hence which do not createsmoke or an aerosol as a result of degradation of, for example, tobaccoby combustion or the process of burning. Examples of such products areso-called heat-not-burn products, tobacco heating products or tobaccoheating devices, which release compounds, which may form an aerosol, byheating, but not burning, aerosol generating material. The aerosolgenerating material may be for example tobacco or other non-tobaccoproducts, which may or may not contain nicotine.

SUMMARY

In accordance with some embodiments described herein, there is providedan article for use with an apparatus for heating aerosol generatingagent to volatilize at least one component of the aerosol generatingagent, the article comprising a support layer having a first surface,wherein at least a portion of the first surface is rough; and an aerosolgenerating agent on the portion of the first surface that is rough.Providing the aerosol generating agent on the portion of the firstsurface that is rough, heat transfer from a heater to the article willbe improved.

In an exemplary embodiment, the portion of the first surface that isrough comprises a plurality of protuberances.

In an exemplary embodiment, the portion of the first surface isembossed. Embossing the first surface is an efficient and easilyrepeatable way to obtain the rough surface.

In accordance with some embodiments described herein, there is providedan article for use with an apparatus for heating aerosol generatingagent to volatilize at least one component of the aerosol generatingagent, the article comprising a first substrate of paper having a firstinner surface; and an aerosol generating agent on at least a portion ofthe first inner surface of the first sheet.

In accordance with some embodiments described herein, there is provideda system comprising an apparatus for heating aerosol generating agent tovolatilize at least one component of the aerosol generating agent; andan article for use with the apparatus for heating aerosol generatingagent to volatilize at least one component of the aerosol generatingagent, the article comprising a support layer having a first surface,wherein at least a portion of the first surface is rough; and an aerosolgenerating agent on the portion of the first surface that is rough.

In accordance with some embodiments described herein, there is provideda kit comprising an apparatus for heating aerosol generating agent tovolatilize at least one component of the aerosol generating agent; andan article for use with the apparatus for heating aerosol generatingagent to volatilize at least one component of the aerosol generatingagent, the article comprising a support layer having a first surface,wherein at least a portion of the first surface is rough; and an aerosolgenerating agent on the portion of the first surface that is rough.

In accordance with some embodiments described herein, there is provideda method of manufacturing a smoking article for use with an apparatusfor heating aerosol generating agent to volatilize at least onecomponent of the aerosol generating agent, the method comprisingproviding a support layer having a first surface, wherein at least aportion of the first surface is rough; and providing an aerosolgenerating agent on the portion of the first surface that is rough.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will now be described, by way of exampleonly, with reference to the accompanying drawings, in which:

FIG. 1 shows a schematic side view of an article for use with anapparatus for heating aerosol generating agent to volatilize at leastone component of the aerosol generating agent.

FIG. 2 shows a schematic perspective view of the article of FIG. 1 .

FIG. 3 shows a schematic perspective view of the first example of anapparatus for heating an aerosol generating material.

FIGS. 4A and 4B show an example of delamination between an aerosolforming agent and a substrate.

FIG. 5 shows a further example of delamination between an aerosolforming agent and a substrate.

FIG. 6 shows a further example of delamination between an aerosolforming agent and a substrate.

FIGS. 7A and 7B shows a schematic plan and perspective view of the firstexample of support layer with a rough first surface for receiving anaerosol generating agent.

FIG. 7C shows a schematic perspective view of a first example of articlefor use with an apparatus for heating aerosol generating agent tovolatilize at least one component of the aerosol generating agent.

FIG. 8 shows a schematic perspective view of a support layer of thearticle with score lines.

FIG. 9 shows a schematic perspective view of a second example of anarticle for use with an apparatus for heating aerosol generating agentto volatilize at least one component of the aerosol generating agent.

FIG. 10 shows a schematic view of an article for use with an apparatusfor heating aerosol generating agent to volatilize at least onecomponent of the aerosol generating agent.

DETAILED DESCRIPTION

As used herein, the term “aerosol generating agent” includes agents thatprovide volatilized components upon heating. “Aerosol generating agent”includes any tobacco-containing material and may, for example, includeone or more of tobacco, tobacco derivatives including tobacco extracts,expanded tobacco, reconstituted tobacco or tobacco substitutes. “Aerosolgenerating agent” may also include other, non-tobacco, products,including for example flavorants, which, depending on the product, mayor may not contain nicotine, filler materials such as chalk and/orsorbent materials, glycerol, propylene glycol or triacetin. The aerosolgenerating agent may also include a binding material, for example,sodium alginate. The aerosol generating agent may include tobaccoparticles or leaves in solid form within the agent. In one example theaerosol generating agent is an aerosol forming gel. The aerosolgenerating gel may be a solid, jelly like material. The aerosolgenerating gel may be a newtonian or non-newtonian gel. In one examplethe gel is a thermoplastic gel. In one example, the aerosol generatinggel has a viscosity of between 0.1 and 100 Ns/m².

Referring to FIGS. 1 to 2 , there is shown an article 100 for use withan apparatus for heating aerosol generating agent to volatilize at leastone component of the aerosol generating agent. The article 100 includesa support layer 102 and a layer of aerosol generating agent 104. Theaerosol generating agent 104 is located on a first surface 106 of thesupport layer 102. The aerosol generating agent 104 forms a layer ofmaterial on the support layer 102 as shown in FIGS. 1 and 2 , forexample the layer of aerosol generating agent 104 is bonded to thesupport layer 102.

In the examples of the articles 100 shown in FIGS. 1 to 6 , the supportlayer 102 has a substantially smooth first surface 106 on which theaerosol generating agent 104 is located. An example of a support layer102 which has a smooth surface is aluminum foil.

The article 100 is designed to be used with an apparatus for heatingaerosol generating agent to volatilize at least one component of theaerosol generating agent, such as a so-called tobacco heating product,which includes a heater. An example of a heating apparatus is shown inFIG. 3 . In one example, the apparatus 50 comprises a substantially flatheating surface 52 upon which, in use, the article 100 is placed suchthat the support layer 102 lies on the heating surface. In otherexamples, the heater may take the form of a cylindrical heater or ablade heater. In other example, the apparatus may comprise a heater toheat air which will subsequently pass over the surface of the aerosolgenerating agent to heat it. The heater may comprise a resistive heater,in another example, the heater may be an inductive heater and thearticle may be placed on a susceptor within the apparatus. In theexample of the induction heating, the support layer 102 may be formed ofa magnetic material and act as an additional susceptor so that an eddycurrent is generated when the support layer 102 is subjected to avarying magnetic field. The apparatus 50 is configured to heat thearticle 100 to volatilize at least one component of the aerosolgenerating agent. In the example of FIG. 3 , the apparatus 50 includes amouthpiece 54 through which the volatilized components may flow.However, in other examples, the apparatus does not include themouthpiece 54.

In the example of the aerosol forming agent 104 comprising an aerosolforming gel, the aerosol forming gel 104 may be formed by mixing aconcentrated tobacco extract with water in a high shear mixer with abinding agent, such as sodium alginate, to form a paste or slurry. Anaerosol generating material, such as glycerol, is added and the paste iswet cast on as a thin film on a support layer 102, such as aluminum orpaper. The thin film is then dried by applying heat to remove excesswater from the film. In the drying phase, the articles 100 may besubject to a temperature of approximately 60 to 100° C. forapproximately 20 minutes to 5 hours. Depending on the chemicals used inthe formulation of the thin films, the thin films exhibit a stickysurface that makes handling them in a commercial environmentproblematic. The thin films may also exhibit poor adhesion to thesupport layer 102 on which they have been cast, which may lead toproblems during the drying phase and also when the article 100 is heatedin use in the aerosol generating apparatus, which will be described inmore detail below.

In one example, the aerosol forming agent 104 has a thickness of between100 µm and 350 µm.

It has been observed that upon heating of the article, the aerosolgenerating agent 104 tends to become delaminated from the support layer102. In addition, when the article 100 is placed on a heating surface 52of the apparatus, the support layer 102 tends to curl, which results ina separation between the support layer 102 and the heating surface 52.The consequence of both of these examples is poor heat transfer from theheating surface 52 to the aerosol generating agent 104, which results ina poor aerosol delivery.

A first mechanism for delamination between the aerosol generating agent104 and the support layer 102 is shown in FIGS. 4A and 4B. FIG. 4A showsan example of the article 100 during heating. The heating process causeswater and or other components within the aerosol generating agent 104 toevaporate causing the agent to contract as shown by the arrows in FIG.3A. The support layer 102 may be formed from a solid material, such asaluminum or paper and thus would not contract upon heating. As there issome adhesion between the aerosol generating material 104 and thesupport layer 102, the differential contraction between the aerosolgenerating agent layer 104 and the support layer 102 causes the article100 to curl as shown in FIG. 3A. The self-weight of the support layer102 causes the support layer 102 to resist the contraction of theaerosol generating agent 104. As the aerosol generating agent 104continues to contract, the central part of the aerosol generating agent104 may separate from the support layer 102 resulting in delamination ofthe aerosol generating agent 104 and the support layer 102. The degreeof curling versus delamination depends on the level of adhesion betweenthe aerosol generating agent 104 and the support layer 102, thestiffness of the support layer 102 and the stiffness of the aerosolforming agent 104.

A second mechanism for delamination between the aerosol generating agent104 and the support layer 102 is shown in FIG. 5 . FIG. 5 shows anexample of the article 100 during heating. The heating process causeswater and or other components within the aerosol generating agent 104 toevaporate. If the support layer 102 is placed on a heating surface 52 ofan apparatus, then the surface of the aerosol generating agent 104 thatis proximate to the first surface 106 of the support layer 102 (andhence the heating surface) will be heated faster compared with thesurface of the aerosol forming agent 104 that is further from theheating surface 52. As a result, the surface of the aerosol generatingagent 104 that is proximate to the first surface 106 of the supportlayer 102 will lose more water compared with the surface of the aerosolforming agent that is further from the heating surface and thereforewill contract more as shown in FIG. 5 .

A third mechanism for delamination between the aerosol generating agent104 and the support layer 102 is shown in FIG. 6 . As the aerosolgenerating agent 104 is heated, at least one component of the aerosolgenerating agent 104 is volatilized. If there is not a flow path betweenthe volatilized component and the outer surface of the aerosolgenerating agent 104, then a build-up of volatilized components will actto separate the aerosol generating agent 104 from the support layer 102.There may also be air bubbles that get trapped in the aerosol generatingagent 104 during the drying process that will expand upon heating andact to cause a delamination between the aerosol generating agent 104 andthe support layer 102.

There is a need to improve heat transfer between a heater of theapparatus 50 and the article 100, which will improve the generation ofvolatilized components. Surprisingly, it was found that improving theadhesion sufficiently improves heat transfer for aerosol generatingagents and results in a more efficient aerosol generating. One way ofimproving heat transfer is to improve adhesion between the aerosolgenerating agent 104 and the support layer 102 to reduce thedelamination between the aerosol generating agent 104 and the supportlayer 102. One option for improving the adhesion between the aerosolgenerating agent 104 and the support layer 102 would be through the useof chemical additives to the aerosol generating agent 104 and thesupport layer 102. Powdered additives may be used to reduce thestickiness of the aerosol generating agent 104 to improve the handlingof the agent. However, the use of additives has a number of drawbacksbecause components from the additives may be volatilized upon heatingand be inhaled by a user, which may be undesirable. Further, the use ofadditives will increase the costs of creating the article 100.

FIGS. 7A and 7B show an example of a support layer 202 in the form of asubstrate having a first surface 206, wherein at least a portion of thefirst surface 206 is rough to provide an uneven or irregular surface.The first surface 206 is sufficiently rough to prevent or inhibit thedelamination of the aerosol generating agent 204 from the first surface206 of the support layer 202.

In one example, the first surface 206 is made rough by making a numberof holes in the support layer 202. The holes may be made by penetratingthe first surface 206 with a pin or series of pins.

The support layer 202 may be formed of any material suitable forreceiving and holding the aerosol generating agent 204. In one example,the support layer 202 is formed from a heat conducting material, forexample a metal such as aluminum. The support layer 202 may be, forexample a metal foil such as aluminum foil.

In the example of the support layer 202 being formed of aluminum, thealuminum can have a thickness of between 5 µm to 25 µm. The aluminumthickness may be 7 µm, 10 µm or 20 µm, such as 6 µm to 8 µm.

In other examples, the support layer 202 is formed from a papermaterial, such as tipping paper, porous plug wrap, cigarette paper ortea bag paper. The paper may be a porous paper. When an aerosolgenerating gel is used as the aerosol generating agent, the gel may flowinto the pores of the porous paper to improve adhesion. In the exampleof the support layer being formed from a paper material, the paper canhave a weight of between 20 gsm and 100 gsm.

The aerosol forming agent 204 (not shown) will be located on the firstsurface 206 of the support layer 202. In the example shown in FIGS. 7Aand 7B, the first surface 206 is rough due to the fact that there is aplurality of protuberances 208. Protuberances 208 are elements thatprotrude from the first surface 206 of the support layer 202. In theexample shown in FIGS. 7A and 7B, the protuberances take the form ofcylinders, however, any shape that projects from the first surface 206of the support layer 202 may be used, such as cubes, pyramids andirregular shapes. It is not necessary for the protuberances 208 to beformed of the same shape. The protuberance 208 in FIGS. 7A and 7B areshown as covering most of the first surface 206 of the support layer202, but in other example, the protuberances 208 only cover part of thefirst surface 206 of the support layer 202. In one example protuberances208 may be formed by adding additional material or removing somematerial from the first surface 206 of the support later.

In one example the protuberances have a height of between 0.1 mm and 0.2mm and a width of between 0.2 mm and 0.4 mm, such as a height of 0.15 mmand a width of 0.3 mm.

In one example, the first surface 206 of the support layer 202 isembossed to create the surface roughness. The support layer 202 may beembossed by stamping the support layer 202 with a mould to cause thefirst surface 206 of support layer 202 to have a three-dimensional orraised effect on selected areas. In some examples, the embossingprocedure requires the use of two dies: one that is raised and one thatis recessed. The dies fit into each other so that when the support layer202 is pressed between them, the raised die forces the support layer 202into the recessed die and creates the embossed surface.

The protuberances 208 may also be formed by embossing. Embossing thefirst surface 206 of the support layer 202 is a simple and repeatableway of creating a rough surface. The first surface 202 may be made roughby including one or more ridges, folds, indents, raised sections, holes.

The first surface 206 may be embossed using various patterns, such asone or more of spirals, lines; squares; circles; and/or rectangles.

The rough first surface 206 of the support layer 202, as shown in FIGS.7A and 7B, acts to increase the contact surface area between the aerosolgenerating agent 204 and the support layer 202. An example of article200 formed from the support layer 202 with a rough first surface 206 andaerosol generating agent 204 is shown in FIG. 7C. The increased surfacearea will increase the adhesion between the aerosol forming agent 204and the support layer 202, and hence reduce the effects of the first twoseparation mechanisms described above. In relation to the firstmechanism, the increased adhesion means that as the aerosol generatingagent 204 contracts, it will be less likely to separate from the supportlayer 202. In relation to the second mechanism, the aerosol formingagent 204 is less likely to separate from the inner surface of the heatconducting layer because it will have a stronger adhesion to the innersurface. As the adhesion is increased, the aerosol forming agent 204 isless likely to delaminate from the support layer 202 and therefore whenthe article 200 is heated by a heating apparatus, more aerosolgenerating agent 204 will be heated.

The article 200 may be manufacturing by providing a support layer 202having a first surface 206, wherein at least a portion of the firstsurface 206 is rough; and providing an aerosol generating agent 204 onthe portion of the first surface 206 that is rough. As described above,the first surface 206 may be made rough by one or more of embossing thefirst surface 206, providing protuberances 208, or other means ofroughening the surface.

In the further example shown in FIG. 8 , the first surface 306 of thesupport layer 302 is made rough by having one or more score lines 310formed in the first surface 306. The score lines may be formed by knownprocesses such as running a cutting element over the first surface 306of the support layer 306 to provide one or more cuts or indents in thefirst surface 306 of the support layer 302.

FIG. 8 shows the support layer 302 with six score lines 310 applied tothe first surface 306, however, in some examples there are fewer scorelines and in other examples there are more than six score lines 310applied to the first surface 306. As with the protuberances 208 shown inFIG. 7B, score lines 310 perform the function of adding a surfaceroughness to the first surface of the support layer 310, which increasesthe adhesion between the aerosol generating agent 304 and the supportlayer 302. In one example, the surface roughness of the first surface306 of the support layer 302 is provided by the score lines 310. Inother examples, the surface roughness of the first surface 306 of thesupport layer is provided by a combination of one or more of theprotuberances 208, embossment and the score lines 310.

As shown in FIG. 9 , the score lines 310 may also be applied to theaerosol generating agent 304. Applying score lines 310 to the aerosolgenerating agent 304 results in the aerosol generating agent 304 beingpooled into one or more separate sections delineated by the score lines310. Separating the aerosol generating agent 304 into separate sectionsprovides more flow paths for any volatilized components and the outersurface of the aerosol generating agent 304. Therefore, the thirdmechanism of delamination between the aerosol generating agent 304 andthe support layer 302 described above is less likely to occur. Further,separating the aerosol generating agent 304 into one or more separatesections helps reduce the curling effect described above.

Aerosol generating agents 104, 204, 304 may be formed from differenttobacco extracts, such as Burley, Virgina and Oriental. Aerosolgenerating agents 204, 304 formed from different tobacco extracts mayhave different properties, for example, agents formed from Burleytobacco is more brittle, whereas agents formed from Virginia andOriental is more pliable. Providing a first surface 306 of a supportlater 302, where at least a portion of the first surface is roughprovides the best results when an aerosol generating agent 304 formedfrom an oriental tobacco is used.

T-Peel tests were carried out on a selection of samples. A T-Peel testinvolves testing the peel strength between the aerosol generating agent304 and the support layer 302. Result of the T-Peel Test are shownbelow:

Agent type Support Layer Thickness Unembossed Embossed Burley 20 µm4.5+/- 0.8 N/mm 6.4+/- 0.6 N/mm Oriental 10 µm 2.3 +/- 0.3 N/mm 3.9 +/-0.8 N/mm

In a yet further example, the support layer 402 may be formed frompaper, such as tipping paper, porous plug wrap, cigarette paper or teabag paper. As paper is a fibrous substrate, the surface of the paperwill be irregular. When an aerosol generating agent is applied to thesurface of the paper, the aerosol generating agent will contact theirregular surface and will adhere to a first surface of the papersubstrate. The inventors found that surprisingly, the aerosol generatingagent 404 did not weaken the thin paper support and upon casting, thepaper retained its integrity and after drying, the thin film adheredstrongly to the paper substrate. This makes an article 400 that uses apaper substrate as the support layer an ideal system for use in aheating apparatus because the paper is thin enough not to act as asignificant “insulation layer” so heat transfer is acceptable.

In one example, the apparatus for heating aerosol generating agent tovolatilize at least one component of the aerosol generating agent may besold in a kit, together with the article according to any of theexamples described above.

The examples above show an aerosol generating agent on a first surfaceof a support layer, however, in other examples the support layer mayinclude a first surface and a second surface, wherein at least a portionof the first surface is rough; and at least a portion of the secondsurface is rough. The second surface may be arranged on the oppositeside of the support layer to the first surface. An aerosol generatingagent is applied to the portion of the first surface that is rough andto the portion of the second surface that is rough. This arrangementenables more aerosol generating agent to be held by the support layer.Alternatively, the article may comprise a second support layer, suchthat the aerosol generating agent is located in between the first andsecond support layers. As with the first support layer the secondsupport layer may comprise a first and/or second surface that are rough.

FIG. 10 shows an example of an article according to any of the exampleabove, wherein the article 500 is in the form of a cartridge that can beinserted into the apparatus 50 for heating aerosol generating agent tovolatilize at least one component of the aerosol generating agent. Thearticle 500 includes a support layer having a first surface (not shown)wherein at least a portion of the first surface is rough. An aerosolgenerating agent is be applied to the portion of the first surface thatis rough.

The various embodiments described herein are presented only to assist inunderstanding and teaching the claimed features. These embodiments areprovided as a representative sample of embodiments only, and are notexhaustive and/or exclusive. It is to be understood that advantages,embodiments, examples, functions, features, structures, and/or otheraspects described herein are not to be considered limitations on thescope of the invention as defined by the claims or limitations onequivalents to the claims, and that other embodiments may be utilizedand modifications may be made without departing from the scope of theclaimed invention. Various embodiments of the invention may suitablycomprise, consist of, or consist essentially of, appropriatecombinations of the disclosed elements, components, features, parts,steps, means, etc, other than those specifically described herein. Inaddition, this disclosure may include other inventions not presentlyclaimed, but which may be claimed in future.

1. An article for use with an apparatus for heating an aerosolgenerating agent to volatilize at least one component of the aerosolgenerating agent, the article comprising: a first substrate of paperhaving a first inner surface; and the aerosol generating agent on atleast a portion of the first inner surface of the first substrate ofpaper.
 2. The article according to claim 1, wherein the first substrateof paper is selected from the group consisting of: tipping paper; porousplug wrap; cigarette paper; and tea bag paper.
 3. The article accordingto claim 1, wherein the first substrate of paper has a measurement fromabout 20 gsm to about 100 gsm.
 4. The article according to claim 1,wherein the first substrate of paper comprises a porous paper.
 5. Thearticle according to claim 1, wherein the aerosol generating agent isadhered to the portion of the first inner surface of the first substrateof paper.
 6. The article according to claim 1, wherein the aerosolgenerating agent comprises an aerosol generating gel.
 7. The articleaccording to claim 1, wherein the aerosol generating agent comprises oneor more tobacco extracts selected from the group consisting of: Burley;Virginia; and Oriental.
 8. The article according to claim 1, wherein theaerosol generating agent has a thickness from about 100 microns to about350 microns on the portion of the first inner surface of the firstsubstrate of paper.
 9. A system comprising: an apparatus for heating anaerosol generating agent to volatilize at least one component of theaerosol generating agent; and an article for use with the apparatus forheating the aerosol generating agent, the article comprising: a firstsubstrate of paper having a first inner surface; and the aerosolgenerating agent on at least a portion of the first inner surface of thefirst substrate of paper.
 10. A kit comprising: an apparatus for heatingan aerosol generating agent to volatilize at least one component of theaerosol generating agent; and an article for use with an apparatus forheating aerosol generating agent to volatilize at least one component ofthe aerosol generating agent, the article comprising: a first substrateof paper having a first inner surface; and the aerosol generating agenton at least a portion of the first inner surface of the first substrateof paper.